In recent years, the burgeoning field of plant-based seafood alternatives has garnered considerable attention, driven by sustainability concerns and the growing demand for ethical food sources. Among the various challenges facing food scientists is the recreation of calamari—a staple seafood item prized for its unique texture. Achieving a plant-based mimic that captures the delicate balance of softness, elasticity, and chewiness characteristic of fried calamari rings has remained elusive, until now. A pioneering research team has unveiled a novel approach that leverages 3D printing technology combined with a precisely formulated plant-based paste, successfully replicating the texture and mouthfeel of real calamari.
This new study, published in ACS Food Science & Technology, builds on previous experiments that explored air-fried vegan calamari composed primarily of microalgae and mung bean proteins. Earlier versions of the product demonstrated promising taste profiles but fell short in texture, particularly regarding the firmness and elasticity that genuine squid rings exhibit after frying. Recognizing the limitations of air frying for this texture-sensitive product, researchers shifted focus to a traditional culinary method — deep-frying battered rings — and optimized both the paste recipe and printing parameters accordingly.
The plant-based paste designed for 3D printing incorporates several key components: mung bean protein isolate, powdered light-yellow microalgae, gellan gum as a stabilizing and thickening agent, and canola oil to simulate the lipid content naturally present in seafood. By manipulating the relative concentrations of these constituents, the research team was able to influence the rheological properties of the paste — its flow and deformation behavior — which directly affects how it can be printed and how the final cooked product feels to the consumer.
Using a food-grade 3D printer, the researchers deposited the composite paste into carefully controlled, layered ring structures approximately 4.5 centimeters in diameter. Unlike prior prototypes, these printed rings underwent an overnight freezing process prior to being coated with batter and promptly deep-fried. This freezing step was found to be critical in preserving and enhancing the structural integrity of the rings during cooking, contributing notably to the final textural fidelity.
Laboratory texture analyses evaluated several parameters integral to mimicking real calamari’s chewiness, including hardness (the force required to deform the sample), springiness (the ability to recover shape after deformation), and cohesiveness (the internal bonding strength of the food matrix). Through iterative testing, the best-performing formulation contained 1.5% gellan gum, 2% canola oil, and 10% powdered microalgae. Microscopic imaging revealed the presence of fine voids within the matrix of this formulation, which contributed to its softness by mimicking the porous nature of natural squid tissue, thereby allowing it to exhibit elasticity and resilience similar to cooked calamari.
Beyond texture, protein content is a crucial nutritional factor. The optimized plant-based calamari was found to contain approximately 19% protein, surpassing the protein levels typically reported in squid meat at about 14%. This suggests not only comparable texture but also favorable nutritional equivalency, or even enhancement, positioning this alternative as an attractive option for protein-conscious consumers seeking sustainable seafood substitutes.
The integration of microalgae, beyond its protein contribution, adds an extra dimension of sustainability and nutrient density. Microalgae are known for their rapid growth cycles and minimal resource demands compared to traditional animal and crop protein sources. Their inclusion enriches the composite paste with beneficial phytochemicals and potentially imparts subtle flavor nuances, helping to close the sensory gap between plant-derived products and marine counterparts.
Lead author Poornima Vijayan articulated the broader implications of this research, highlighting the transformative potential of 3D printing in food science. By combining emerging fabrication technologies with sustainable ingredients, researchers can tailor complex food structures that closely mimic the organoleptic properties of animal-based foods, opening doors to novel culinary experiences and environmentally friendly consumption patterns. The team’s forthcoming objectives focus on consumer acceptance studies, which will assess sensory perceptions and market viability, as well as scaling up production for wider application.
The methodical approach taken by the research team exemplifies the intersection of material science, chemistry, and culinary arts. The fine-tuning of the paste’s rheology—its deformation and flow attributes—was essential not only for ensuring the material could be precisely extruded layer by layer but also for guaranteeing that it retained the functional characteristics required for the cooking process and eventual eating experience.
This endeavor also involved collaborations and funding from esteemed institutions, including the National University of Singapore and the Commonwealth Research Scholarship, with additional backing by Singapore’s National Research Foundation under the CREATE program. CREATE fosters interdisciplinary research aimed at practical solutions that serve economic and societal needs, particularly in domains such as environmental sustainability and food security.
The complex matrix of gellan gum and canola oil in tandem with plant proteins illustrates how polysaccharides and lipids can substitute for components in natural seafood, whose texture arises not only from muscle proteins but also from their interactive microstructure. The successful emulation of firmness and chewiness validates the hypothesis that edible gels and emulsions can replace animal tissue’s mechanical behavior when engineered thoughtfully.
Overall, this breakthrough is a testament to how convergent technologies—3D printing, food chemistry, and plant biochemistry—can address pressing global challenges by creating palatable, nutritious, and sustainable alternatives to traditional seafood. As the global appetite for sustainable proteins grows alongside environmental concerns, such innovations hold promise to disrupt conventional food systems and reduce the ecological footprint of human diets.
In conclusion, the advent of 3D-printed, plant-based calamari that rivals traditional seafood in texture and protein content marks a significant advance in the quest for sustainable, cruelty-free dining options. By replicating the intricate textural traits through guided manipulation of ingredient composition and processing methods, this research charts a practical pathway toward widely adoptable seafood analogs. Future consumer studies and scale-up efforts will determine their place in everyday diets, potentially revolutionizing the seafood market with greener, health-conscious, and ethically inspiring alternatives.
Subject of Research: Plant-based seafood alternatives; 3D printing applications in food; food texture and rheology; protein-based food design.
Article Title: “3D Printing for Seafood Mimic: Factors Impacting the Rheology and Texture of Microalgae and Mung Bean Protein Composite Ink”
News Publication Date: 22-Mar-2025
Web References:
https://www.create.edu.sg
DOI link
References:
Vijayan, P., Huang, D., et al. “3D Printing for Seafood Mimic: Factors Impacting the Rheology and Texture of Microalgae and Mung Bean Protein Composite Ink.” ACS Food Science & Technology, 2025.
Image Credits: Adapted from ACS Food Science & Technology 2025, DOI: 10.1021/acsfoodscitech.4c00852
Keywords
Chemistry, Plant proteins, Food science, Food chemistry, Vegetarianism
